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Free Download Air-Cooled Heat Exchangers API 661 Design & Diagnosis
Published 8/2026
MP4 | Video: h264, 1920x1080 | Audio: AAC, 44.1 KHz, 2 Ch
Language: English | Duration: 3h 43m | Size: 2.2 GB
Fin fan design, bundle and header selection, fans and drives, winterisation, fouling and the reactor effluent problem
What you'll learn
Size and rate an air-cooled heat exchanger to a first-pass level and identify which assumptions the answer depends on
Select the design air temperature deliberately, and quantify what summer and winter operation will actually do to duty
Choose between forced and induced draft, and between header types, on the real engineering trade-offs
Diagnose lost duty - separating air-side fouling, tube-side fouling, recirculation, fan problems and plugged tubes
Understand why the air-side film dominates, and select fin type, pitch, face velocity and row count accordingly
Specify fans, drives and air flow control including variable pitch, variable speed and louvres
Design winterisation and freeze protection for cold climate and freezing service
Apply the Requirements of API 661 and identify the datasheet fields that carry the most risk
Assess the reactor effluent air cooler problem - ammonium bisulfide corrosion, velocity limits and symmetrical inlet piping
Judge tube plugging limits, retubing and bundle replacement, and the access and rigging each requires
Requirements
No prior heat exchanger design experience is required - the principles are built up from the start
Any engineering or technical background is enough to follow the course
Comfortable with basic algebra - every relationship is explained before it is used
Helpful but not essential: some familiarity with reading a process flow diagram or equipment datasheet
No software or purchases needed - this is an applied design and reliability course
Description
This course contains the use of artificial intelligence.
On the hottest day of the year, when the plant most wants to run at rate, the air coolers are the reason it cannot. That is the defining characteristic of this equipment and it is the one thing most training never explains.
Air-cooled exchangers are on every process plant, gas plant and refinery built in the last forty years, and water scarcity means more are being specified every year. They are also taught almost nowhere. Engineers inherit them, live with their seasonal behaviour, and are asked to explain a summer bottleneck they were never given the tools to analyse.
This course gives you those tools, from thermal design through to the failures that take a bundle out of service.
WHAT YOU WILL MASTER
Five sections cover configurations and terminology, thermal design and ambient sensitivity, construction and the Requirements of API 661, fans and air flow control, and service problems through to inspection and bundle replacement.
You will understand why the air-side film dominates the design and what that means for fin selection, face velocity and row count. You will select a design ambient temperature and understand exactly what you have committed the plant to when you do. You will choose between forced and induced draft on the real trade-offs rather than on precedent, and you will size a bundle to a first-pass level and know which assumptions the answer rests on.
CONSTRUCTION THAT DETERMINES SERVICE LIFE
Plug, cover plate and bonnet headers and the pressure, temperature and fouling conditions that select between them. Embedded, extruded, wrapped and welded fins, the temperature limit of each, and how fin bond loss quietly removes surface area you are still paying to cool with. Tube-to-header joints, structure and plenum, thermal growth and the access you will need long after handover.
THE REACTOR EFFLUENT AIR COOLER
A dedicated lesson on the highest-consequence application of this equipment. Ammonium bisulfide corrosion, velocity limits, the parameter used to judge severity, symmetrical inlet piping, and the industry failures that shaped current guidance. If you work in hydroprocessing, this lesson alone justifies the course.
WHEN PERFORMANCE FALLS AWAY
Air-side fouling from dust, insects and vegetation. Tube-side fouling and the approach trend that reveals it. Tube-to-header leakage, header box cracking, corrosion under fins, and drive train vibration. Tube plugging limits and their real cost in lost duty, and the decision between retubing and bundle replacement.
WHO THIS IS FOR
Process and equipment engineers specifying or rating air coolers; mechanical engineers reviewing vendor designs and datasheets; reliability and maintenance engineers dealing with fouling, leakage and fan problems; operations engineers explaining a summer constraint; and project engineers buying this equipment as part of a package.
WHAT YOU GET
Structured on-demand video across 20 focused lessons and five sections, a final exam, downloadable lectures, lifetime access on mobile and TV and a certificate of completion.
No prior heat exchanger design experience is required - the thermal principles are built up from the start. Any engineering or technical background is enough to follow it.
Enrol now and stop treating the air coolers as the part of the plant nobody understands.
Who this course is for
Process and equipment engineers specifying, rating or reviewing air-cooled heat exchangers
Mechanical engineers assessing vendor designs, datasheets and bundle construction
Reliability and maintenance engineers dealing with fouling, tube leaks, fan and drive problems
Operations and technical support engineers explaining seasonal capacity constraints
Project and package engineers buying air coolers within a larger equipment scope
Graduate engineers entering process or equipment roles and meeting this equipment for the first time
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